LCD panel having a broad-gap region having a dent within a non-display region of the panel and an electrical transfer section and a sealing portion both at least partially within the dent for first and second substrates forming the panel

ABSTRACT

The method of the present invention includes the steps of: (A) providing a first substrate, and a second substrate, wherein the first substrate includes a first light shielding layer provided within a non-display region, the first light shielding layer including a light-transmitting portion provided near an outer boundary of the first light shielding layer, the light-transmitting portion comprising a recess or an opening; (B) drawing a seal pattern with a sealant, the seal pattern being drawn outside the first light shielding layer so as to surround the display region, comprising the substeps of: (B1) beginning application of the sealant near the light-transmitting portion, (B2) applying the sealant along an outer periphery of the first light shielding layer, and (B3) forming a junction with the sealant having been applied near the light-transmitting portion; (C) applying a liquid crystal material within the display region surrounded by the sealant; (D) attaching the first substrate and the second substrate; and (E) performing light irradiation from the first substrate side to cure the sealant.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a liquid crystal display panel and amethod for producing the same. More particularly, the present inventionrelates to a method for producing a liquid crystal display panel byusing one drop filling technique, and a liquid crystal display panelsuitable for such a production method.

2. Description of the Related Art

In recent years, as liquid crystal display panels become larger in size,it is becoming more common to adopt a so-called one drop fillingtechnique as a method for forming a liquid crystal layer between a pairof substrates, instead of the conventionally-used vacuum injectiontechnique.

A process of producing a liquid crystal display panel using a vacuuminjection technique comprises the following steps.

(a1) On one of a pair of substrates (which typically are a color filtersubstrate and a TFT substrate) for composing a liquid crystal displaypanel, a predetermined pattern of sealant is formed. Thereafter, thepair of substrates are attached together, and the sealant is cured,whereby a liquid crystal cell is obtained. The sealant pattern is formedso as to define a region in which a liquid crystal layer will later beformed (note that a display region is encompassed within this region)and also to define an injection inlet.

(a2) After evacuating the liquid crystal cell to create a vacuumtherein, a liquid crystal material is injected while keeping the liquidcrystal material in contact with the injection inlet, by utilizing apressure difference between the interior and exterior of the liquidcrystal cell and also utilizing capillary action.

(a3) Thereafter, the injection inlet is sealed with an encapsulant.

On the other hand, a one drop filling technique comprises the followingsteps.

(b1) On one of a pair of substrates, a sealant pattern is formed so asto surround a region in which a liquid crystal layer is to be formed,and thereafter a liquid crystal material is dripped into the regionenclosed by the sealant pattern.

(b2) Then, the substantially is attached to the other substrate, andthereafter the sealant is cured.

In the one drop filling technique, the sealant pattern needs tocompletely enclose the region in which to form a liquid crystal layer.Therefore, when a seal pattern is drawn by means of a dispenser or thelike, at least one junction will always be formed.

With reference to FIG. 21, the characteristics of a seal pattern used inthe one drop filling technique will be described.

FIG. 21 illustrates an example where four liquid crystal display panelsare to be formed from a mother substrate. A color filter mothersubstrate 20 includes four color filter substrates. In a display region24 of each resultant color filter substrate, color filters which arearranged so as to correspond to the pixels and a counter electrode(s)(which are not shown) are provided. Each color filter substrate furtherincludes a light shielding layer (black matrix) 22 surrounding thedisplay region 24, such that the light shielding layer 22 defines anouter periphery of the display region 24. Although FIG. 21 onlyillustrates discrete TFT substrates 10 corresponding to the respectiveliquid crystal display panels, it will be appreciated that a mothersubstrate including four unseparated TFT substrates 10 (in a similarfashion to the color filter mother substrate 20) is to be attached tothe mother substrate 20 before cutting. In a display region 14 of eachof the four TFT substrates 10, necessary circuit elements, e.g., TFTs,pixel electrodes, gate bus lines, and source bus lines, are formed. EachTFT substrate and each color filter substrate are attached together bymeans of a sealing portion 32. The sealing portion 32 is formed on theoutside of the light shielding layer 22.

The portion of the liquid crystal display panel lying outside of thedisplay region 14 is referred to as a “non-display region” or “frameregion”, which is expected to be as narrow as possible. The lightshielding layer 22 and the sealing portion 32 are provided in thenon-display region.

On the other hand, the light shielding layer 22 needs to have a certainthickness in order to prevent unnecessary light from entering into thedisplay region 14. If light shielding is insufficient, black displayingquality is degraded, thus substantially affecting the image quality. Inorder to satisfy both of these requirements, it is necessary toaccurately form the sealing portion 22 at the close vicinity of theouter periphery of the light shielding layer 22.

However, when the sealing portion 32 is formed by a drawing technique,at least one junction 32 b will inevitably be formed. The sealingjunction 32 b tends to become thicker than a main stretch 32 a of thesealing. As used herein, the sealing main stretch 32 a refers to aportion of the sealing portion 32, excluding the junction 32 b, that hasa substantially constant width. The main stretch 32 a is a portion of aseal pattern that is created with a sealant which is discharged while anozzle of a dispenser or the like undergoes a relative movement withinthe plane of the substrate, and therefore depends on the dischargedamount of sealant and the moving speed of the nozzle. Thus, the mainstretch 32 a has a fairly stable width. On the other hand, the junction32 b includes a portion at which the sealant is first applied (i.e., astart point of the seal drawing). The amount of sealant which isinitially added depends on the amount of sealant which resides at thetip of the nozzle. The amount of sealant residing at the tip of thenozzle fluctuates due to fluctuations in the length of time spent forpositioning the nozzle (including positioning along the heightdirection), and fluctuations in the amount of sealant which remains atthe tip of the nozzle when the nozzle is lifted off the substrate at theend point of seal drawing. Thus, due to the inconstancy in the amount ofsealant applied at the start point and end point of seal drawing, andthe need to form a junction, the width of the junction 32 b tends tobecome thicker than that of the main stretch 32 a.

FIGS. 22A and 22B are enlarged views showing the neighborhood of asealing junction. FIG. 22A is a plan view, and FIG. 22B is across-sectional view.

As described above, if the seal pattern has a broader width at thejunction 32 b, a portion thereof may overlap the light shielding layer22. Since photocurable resins (including those types of photocurableresin which also allow auxiliary use of thermosetting) are widely usedas the sealant, if light irradiation (typically ultraviolet (UV)irradiation) is performed from the side of the color filter substrate20, the portion 32′ of the sealant which overlaps with the lightshielding layer 22 cannot be sufficiently cured. As a result, theuncured component of the photocurable resin may elute into the liquidcrystal material, thus causing deterioration in reliability, e.g.,lowering of the voltage retention rate of the liquid crystal displaypanel mainly due to ionic components, and occurrence of orientationdefects.

It might be possible to perform light irradiation from the side of theTFT substrate 10. However, as will be described later, if UV irradiationis performed from the side of the TFT substrate 10, it becomes necessaryto employ some means for preventing the TFTs from being irradiated withUV (e.g., a mask for shielding the TFTs from light must be used). On theother hand, if UV irradiation is performed from the side of the colorfilter substrate 20, there is an advantage in that such means can beomitted in the case where the color filter sufficiently absorbs UV. Atleast the amount of damage to the TFTs can be reduced.

In order to prevent partial overlapping between the junction 32 b andthe light shielding layer 22, Japanese Laid-Open Patent Publication No.2002-122870 discloses a method which involves drawing a seal patternthat extends to the outside of the liquid crystal display panel, andforming a junction 32 d outside of the liquid crystal display panel, asshown in FIG. 23. Moreover, as shown in FIG. 24, Japanese Laid-OpenPatent Publication No. 2002-122870 discloses a method which involvesforming a start or end point 32 e of seal drawing outside of the liquidcrystal display panel.

Japanese Laid-Open Patent Publication No. 8-240807 discloses a methodwhich involves forming a sealing junction at a corner portion, takingadvantage of the fact that the interspace between a sealing portion anda light shielding portion will be about 1.4 times greater at a cornerportion of the liquid crystal display panel than along any side thereof.However, this method cannot cope with the above problem once the widthof the sealing junction exceeds about 1.4 times the aforementionedvalue, as is also pointed out in Japanese Laid-Open Patent PublicationNo. 2002-122870.

If the method described in Japanese Laid-Open Patent Publication No.2002-122870 is used, it is no longer necessary to form a junction 32 bwithin the liquid crystal display panel. However, as shown in FIG. 25A,this method is only applicable to the case where, after a TFT substrate(TFT mother substrate) 10 is attached to a color filter substrate (CFmother substrate) 20, both mother substrates 10 and 20 are cut along thesame line CL. There exist other cases where, as shown in FIG. 25B, theTFT mother substrate 10 is cut along a cut line CL1 and the CF mothersubstrate 20 is cut along a cut line CL2 different from the cut lineCL1, this being in order to provide a signal line terminal section(driver mounting portion) on the TFT substrate 10. In such cases, thereis a problem in that a sealing portion 32 t will remain on the TFTmother substrate 10, which will stick to a fragment of the CF mothersubstrate 20 to be removed, thus making it impossible to remove thefragment. Note that in a structure where signal line terminal sectionsare provided along three or four sides of the liquid crystal displaypanel in order to suppress signal delays and the like associated with anincreased size of the display panel, it is impossible to adopt the sealpattern as shown in FIG. 25A. Although the pattern shown in FIG. 25A canbe adopted in the case where signal line terminal sections are providedalong two sides of the liquid crystal display panel, the need to cut thesealing portion 32 concurrently with the mother substrates 10 and 20 mayinvite cutting failures.

Furthermore, the method described in Japanese Laid-Open PatentPublication No. 2002-122870 will require an apparatus which is able todraw a seal pattern to the outside of a liquid crystal display panelwithout allowing a junction to be formed before going out of the displaypanel. Such a seal pattern drawing apparatus will inevitably be large insize, and hence increase the production cost of the display panel.

According to a study conducted by the inventors of the presentinvention, the method described in Japanese Laid-Open Patent PublicationNo. 8-240807 will have not only the problem mentioned in JapaneseLaid-Open Patent Publication No. 2002-122870, but also another problemin that, as schematically shown in FIGS. 26A and 26B, the width of thesealing junction may occasionally exceed the 1.4 times value at a cornerportion, even without forming a junction. In such cases, the sealant 32c present in the overlapping portion with the light shielding layer 22cannot be sufficiently cured.

In addition to sealing junctions and corner portions, similar methodsmay also occur in any transfer section for establishing electricalconnection between the upper and lower substrates (e.g., a commontransfer section).

SUMMARY OF THE INVENTION

In order to overcome the problems described above, preferred embodimentsof the present invention provide: a method for efficiently producing aliquid crystal display panel whose reliability will not be degraded evenif a portion (e.g., a sealing junction or transfer section) which underthe conventional production methods will result in a seal pattern havinga thicker width is formed in the liquid crystal display panel; and aliquid crystal display panel which is provided by such a productionmethod.

A liquid crystal display panel production method according to thepresent invention is a method for producing a liquid crystal displaypanel including a first substrate, a second substrate, and a liquidcrystal layer interposed between the first substrate and the secondsubstrate, the liquid crystal display panel having a display region anda non-display region surrounding the display region, the methodcomprising the steps of: (A) providing the first substrate or a firstmother substrate containing the first substrate, and the secondsubstrate or a second mother substrate containing the second substrate,wherein the first substrate includes a first light shielding layerprovided within the non-display region at an end closer to the displayregion, the first light shielding layer including at least onelight-transmitting portion provided near an outer boundary of the firstlight shielding layer, the at least one light-transmitting portioncomprising a recess or an opening; (B) drawing a seal pattern by using asealant containing a photocurable resin, the seal pattern being drawnoutside the first light shielding layer of the first substrate so as tosurround the display region, comprising the substeps of: (B1) beginningapplication of the sealant near the light-transmitting portion of thefirst substrate, (B2) applying the sealant along an outer periphery ofthe first light shielding layer of the first substrate, and (B3) forminga junction with the sealant having been applied near thelight-transmitting portion; (C) applying a liquid crystal materialwithin the display region surrounded by the sealant; (D) attachingtogether the first substrate and the second substrate, with the liquidcrystal material interposed therebetween; and (E) after step (D),performing light irradiation from the first substrate side to cure thesealant.

In one embodiment, the first substrate has a rectangular shape; the atleast one light-transmitting portion includes a light-transmittingportion provided at least along a side of the rectangular shape; and thejunction is formed at the light-transmitting portion provided along theside of the rectangular shape.

In one embodiment, the at least one light-transmitting portion includestwo or more light-transmitting portions provided along the side of therectangular shape; and the junction is formed at each of the two or morelight-transmitting portions formed along the side of the rectangularshape.

In one embodiment, the at least one light-transmitting portion furtherincludes a light-transmitting portion provided at a corner of therectangular shape.

In one embodiment, the first mother substrate includes a plurality offirst substrates, the method comprising: a first drawing step of drawingthe seal pattern on one of the plurality of first substrates bybeginning application of the sealant near one of the two or morelight-transmitting portions of the first substrate, applying the sealantalong the outer periphery of the first light shielding layer, and endingapplication of the sealant near another of the two or morelight-transmitting portions; a second drawing step of drawing the sealpattern on another of the plurality of first substrates by beginningapplication of the sealant near one of the two or morelight-transmitting portions of the first substrate, applying the sealantalong the outer periphery of the first light shielding layer, and endingapplication of the sealant near another of the two or morelight-transmitting portions; a third drawing step of, after the firstdrawing step, drawing the seal pattern on the one first substrate bybeginning application of the sealant so as to form a junction with thesealant having been applied near the one light-transmitting portion orthe other light-transmitting portion of the first substrate; and afourth drawing step of, after the second drawing step, drawing the sealpattern on the other first substrate by beginning application of thesealant so as to form a junction with the sealant having been appliednear the one light-transmitting portion or the other light-transmittingportion of the first substrate.

Another liquid crystal display panel production method according to thepresent invention is a method for producing a liquid crystal displaypanel including a first substrate, a second substrate, and a liquidcrystal layer interposed between the first substrate and the secondsubstrate, the liquid crystal display panel having a display region anda non-display region surrounding the display region, the methodcomprising the steps of: (A) providing the first substrate or a firstmother substrate containing the first substrate, and the secondsubstrate or a second mother substrate containing the second substrate,wherein the first substrate includes a first light shielding layerprovided within the non-display region at an end closer to the displayregion, the first light shielding layer including at least onelight-transmitting portion provided near an outer boundary of the firstlight shielding layer, the at least one light-transmitting portioncomprising a recess or an opening; (B) drawing a seal pattern by using asealant containing a photocurable resin, the seal pattern being drawn ina region of the second substrate to be located outside the first lightshielding layer of the first substrate when the second substrate isattached to the first substrate, and the seal pattern being drawn so asto surround the display region, comprising the substeps of: (B1)beginning application of the sealant near a position corresponding tothe light-transmitting portion of the first substrate, (B2) applying thesealant along a region corresponding to an outer periphery of the firstlight shielding layer of the first substrate, and (B3) forming ajunction with the sealant having been applied near the positioncorresponding to the light-transmitting portion; (C) applying a liquidcrystal material within the display region surrounded by the sealant;(D) attaching together the first substrate and the second substrate,with the liquid crystal material interposed therebetween; and (E) afterstep (D), performing light irradiation from the first substrate side tocure the sealant.

In one embodiment, the first substrate has a rectangular shape; the atleast one light-transmitting portion includes a light-transmittingportion provided at least along a side of the rectangular shape; and thejunction is formed at a position corresponding to the light-transmittingportion provided along the side of the rectangular shape.

In one embodiment, the at least one light-transmitting portion includestwo or more light-transmitting portions provided along the side of therectangular shape; and the junction is formed at a positioncorresponding to each of the two or more light-transmitting portionsformed along the side of the rectangular shape.

In one embodiment, the at least one light-transmitting portion furtherincludes a light-transmitting portion provided at a corner of therectangular shape.

In one embodiment, the second mother substrate includes a plurality ofsecond substrates, the method comprising: a first drawing step ofdrawing the seal pattern on one of the plurality of second substrates bybeginning application of the sealant near a position corresponding toone of the two or more light-transmitting portions of the firstsubstrate, applying the sealant along the region corresponding to theouter periphery of the first light shielding layer, and endingapplication of the sealant near a position corresponding to another ofthe two or more light-transmitting portions; a second drawing step ofdrawing the seal pattern on another of the plurality of secondsubstrates by beginning application of the sealant near a positioncorresponding to one of the two or more light-transmitting portions ofthe first substrate, applying the sealant along the region correspondingto the outer periphery of the first light shielding layer, and endingapplication of the sealant near a position corresponding to another ofthe two or more light-transmitting portions; a third drawing step of,after the first drawing step, drawing the seal pattern on the one secondsubstrate by beginning application of the sealant so as to form ajunction with the sealant having been applied near the positioncorresponding to the one light-transmitting portion or the positioncorresponding to the other light-transmitting portion of the firstsubstrate; and a fourth drawing step of, after the second drawing step,drawing the seal pattern on the other second substrate by beginningapplication of the sealant so as to form a junction with the sealanthaving been applied near the position corresponding to the onelight-transmitting portion or the position corresponding to the otherlight-transmitting portion of the first substrate.

In one embodiment, the liquid crystal display panel has a broad-gapregion within the non-display region, the broad-gap region being aregion in which a gap between the first substrate and the secondsubstrate is partially increased, the broad-gap region comprising a dentin a surface of the first substrate or the second substrate; and the atleast one light-transmitting portion includes a light-transmittingportion provided near the broad-gap region.

In one embodiment, the liquid crystal display panel production methodfurther comprises a step of applying a transfer material containing aphotocurable resin to the first substrate or the second substrate forforming a transfer section for establishing electrical connectionbetween the first substrate and the second substrate, wherein thetransfer material is applied in the dent.

In one embodiment, the liquid crystal display panel production methodfurther comprises a step of applying a transfer material containing aphotocurable resin to the first substrate or the second substrate forforming a transfer section for establishing electrical connectionbetween the first substrate and the second substrate, wherein thetransfer material is applied at a position on the first substrate nearthe at least one light-transmitting portion, or near a position on thesecond substrate corresponding to the light-transmitting portion of thefirst substrate.

In one embodiment, step (E) comprises a substep of curing the transfermaterial via the light irradiation.

In one embodiment, the transfer section is formed so as to at leastpartially overlap with the seal pattern.

In one embodiment, the second substrate includes at least one secondlight shielding layer in the non-display region, the at least one secondlight shielding layer being provided in a region corresponding to the atleast one light-transmitting portion of the first substrate.

In one embodiment, the second substrate includes a source bus line and agate bus line; and the at least one second light shielding layercomprises a same conductive layer as that of the source bus line or thegate bus line.

In one embodiment, the at least one light-transmitting portion comprisesa plurality of recess or openings, the second light shielding layerfurther including light-transmitting portions provided corresponding tointerspaces between, or neighborhoods of, the plurality of recesses oropenings, the method further comprising, after step (D), a step ofperforming light irradiation from the second substrate side.

A still another liquid crystal display panel production method accordingto the present invention is a method for producing a liquid crystaldisplay panel including a first substrate, a second substrate, and aliquid crystal layer interposed between the first substrate and thesecond substrate, the liquid crystal display panel having a displayregion, a non-display region surrounding the display region, and abroad-gap region within the non-display region, the broad-gap regionbeing a region in which a gap between the first substrate and the secondsubstrate is partially increased, the broad-gap region comprising a dentin a surface of the first substrate or the second substrate, the methodcomprising the steps of: (A) providing the first substrate or a firstmother substrate containing the first substrate, and the secondsubstrate or a second mother substrate containing the second substrate,wherein the first substrate includes a first light shielding layerprovided within the non-display region at an end closer to the displayregion; (B) drawing a seal pattern by using a sealant containing aphotocurable resin, the seal pattern being drawn outside the first lightshielding layer of the first substrate having the dent, or the sealpattern being drawn in a region of the second substrate to be locatedoutside the first light shielding layer of the first substrate when thesecond substrate having the dent is attached to the first substrate, theseal pattern being drawn so as to surround the display region,comprising the substeps of: (B1) beginning application of the sealantnear the dent of the first substrate or the second substrate, (B2)applying the sealant along an outer periphery of the first lightshielding layer of the first substrate, or along a region on the secondsubstrate corresponding to the outer periphery of the first lightshielding layer of the first substrate, and (B3) forming a junction withthe sealant having been applied near the dent; (C) applying a liquidcrystal material within the display region surrounded by the sealant;(D) attaching together the first substrate and the second substrate,with the liquid crystal material interposed therebetween; and (E) afterstep (D), performing light irradiation to cure the sealant.

A still another liquid crystal display panel production method accordingto the present invention is a method for producing a liquid crystaldisplay panel including a first substrate, a second substrate, and aliquid crystal layer interposed between the first substrate and thesecond substrate, the liquid crystal display panel having a displayregion, a non-display region surrounding the display region, and abroad-gap region within the non-display region, the broad-gap regionbeing a region in which a gap between the first substrate and the secondsubstrate is partially increased, the broad-gap region comprising a dentin a surface of the first substrate or the second substrate, the methodcomprising the steps of: (A) providing the first substrate or a firstmother substrate containing the first substrate, and the secondsubstrate or a second mother substrate containing the second substrate,wherein the first substrate includes a first light shielding layerprovided within the non-display region at an end closer to the displayregion; (B) drawing a seal pattern by using a sealant containing aphotocurable resin, the seal pattern being drawn outside the first lightshielding layer of the first substrate having the dent, or the sealpattern being drawn in a region of the second substrate to be locatedoutside the first light shielding layer of the first substrate when thesecond substrate having the dent is attached to the first substrate, theseal pattern being drawn so as to surround the display region; (B′)applying a transfer material containing a photocurable resin to thefirst substrate or the second substrate for forming a transfer sectionfor establishing electrical connection between the first substrate andthe second substrate, the transfer material being applied in the dent;(C) applying a liquid crystal material within the display regionsurrounded by the sealant; (D) attaching together the first substrateand the second substrate, with the liquid crystal material interposedtherebetween; and (E) after step (D), performing light irradiation tocure the sealant.

In one embodiment, step (B) comprises a substep of (B1) beginningapplication of the sealant from the dent of the first substrate or thesecond substrate.

In one embodiment, the liquid crystal display panel production methodfurther comprises a step of forming the dent, wherein the step offorming the dent comprises a substep of forming a throughhole or hole ina photosensitive resin layer of a positive or negative type.

In one embodiment, the liquid crystal display panel production methodfurther comprises a step of forming the dent, wherein the step offorming the dent comprises a substep of forming a hole in thephotosensitive resin layer by using a half exposure technique.

In one embodiment, the first substrate includes a color filter in thedisplay region.

A liquid crystal display panel according to the present invention is aliquid crystal display panel including a first substrate, a secondsubstrate, a liquid crystal layer interposed between the first substrateand the second substrate, and a sealing portion surrounding the liquidcrystal layer, the liquid crystal display panel having a display regionand a non-display region surrounding the display region, wherein, thefirst substrate includes a first light shielding layer provided withinthe non-display region at an end closer to the display region, the firstlight shielding layer including at least one light-transmitting portionprovided near an outer boundary of the first light shielding layer, theat least one light-transmitting portion comprising a recess or anopening; and the sealing portion has a broadened width at the at leastone light-transmitting portion.

Another liquid crystal display panel according to the present inventionis a liquid crystal display panel including a first substrate, a secondsubstrate, a liquid crystal layer interposed between the first substrateand the second substrate, a sealing portion surrounding the liquidcrystal layer, and a transfer section for establishing electricalconnection between the first substrate and the second substrate, theliquid crystal display panel having a display region and a non-displayregion surrounding the display region, wherein, the first substrateincludes a first light shielding layer provided within the non-displayregion at an end closer to the display region, the first light shieldinglayer including at least one light-transmitting portion provided near anouter boundary of the first light shielding layer, the at least onelight-transmitting portion comprising a recess or an opening; and atleast a part of the transfer section is provided in the at least onelight-transmitting portion.

In one embodiment, the first substrate includes a color filter in thedisplay region.

In one embodiment, the second substrate includes at least one secondlight shielding layer in the non-display region, the at least one secondlight shielding layer being provided in a region corresponding to the atleast one light-transmitting portion of the first substrate.

In one embodiment, the second substrate includes a source bus line and agate bus line; and the at least one second light shielding layercomprises a same conductive layer as that of the source bus line or thegate bus line.

In one embodiment, the at least one light-transmitting portion comprisesslit-like recesses or openings; and the at least one second lightshielding layer includes a plurality of light shielding portionsprovided so as to oppose the slit-like recesses or openings.

A still another liquid crystal display panel according to the presentinvention is a liquid crystal display panel including a first substrate,a second substrate, a liquid crystal layer interposed between the firstsubstrate and the second substrate, a sealing portion surrounding theliquid crystal layer, and a transfer section for establishing electricalconnection between the first substrate and the second substrate, theliquid crystal display panel having a display region and a non-displayregion surrounding the display region, wherein, the liquid crystaldisplay panel includes a broad-gap region within the non-display region,the broad-gap region being a region in which a gap between the firstsubstrate and the second substrate is partially increased, the broad-gapregion comprising a dent in a surface of the first substrate or thesecond substrate; and the transfer section is provided in the dent.

A still another liquid crystal display panel according to the presentinvention is a liquid crystal display panel including a first substrate,a second substrate, a liquid crystal layer interposed between the firstsubstrate and the second substrate, and a sealing portion surroundingthe liquid crystal layer, the liquid crystal display panel having adisplay region and a non-display region surrounding the display region,wherein, the liquid crystal display panel includes a broad-gap regionwithin the non-display region, the broad-gap region being a region inwhich a gap between the first substrate and the second substrate ispartially increased, the broad-gap region comprising a dent in a surfaceof the first substrate or the second substrate; and a part of thesealing portion is provided in the dent.

In one embodiment, the dent comprises a throughhole or hole formed in aphotosensitive resin layer of a positive or negative type.

In accordance with a liquid crystal display panel production method ofthe present invention, a substrate including a light shielding layerwhich has a light-transmitting portion (recess or opening) at a positionto become a junction of a sealant is used, and light irradiation isperformed from the side of this substrate. As a result, insufficientsealant curing at the junction is prevented. Moreover, by providing alight-transmitting portion at a corner portion or a transfer section(e.g., a common transfer section) at which the width of the seal patternis likely to become broadened, curing failure of the sealant at such acorner portion or transfer section can also be prevented. Thus, since alight-transmitting portion is provided only in a portion(s) of the lightshielding layer at which the width of the seal pattern is expected tobecome thick, the width of the non-display region can be kept narrow.Furthermore, by providing a light shielding layer on another substrate(at a position opposing the position at which the light-transmittingportion is provided on the first substrate), the original purpose of thelight shielding layer, i.e., prevention of light leakage, will not beundermined.

Since it is unnecessary to form a sealing portion outside the liquidcrystal display panel, failures during the cutting of the mothersubstrate are prevented. Furthermore, by providing two or more junctionsin the liquid crystal display panel, an increased freedom is obtainedwith respect to the drawing order of the seal pattern, and/or it becomespossible to perform a simultaneous drawing using a plurality ofdispensers, whereby the tact time of the seal drawing process can bereduced. By providing two or more junctions in the seal pattern, itbecomes possible to perform a seal pattern drawing on the large-sizedliquid crystal display panel by using a relatively small seal patterndrawing apparatus, whereby an increase in the production cost can besuppressed.

By using a color filter substrate as the aforementioned substrate,damage to the TFTs due to UV can be reduced. Furthermore, it becomespossible to omit a mask to be used for protecting the TFTs in the lightirradiation process. By performing light irradiation also from the TFTsubstrate side, the irradiation time required for the curing can bereduced.

In accordance with the liquid crystal display panel production method ofthe present invention, a dent is provided in a surface of the substrateat a portion at which the seal pattern is expected to have a broadenedwidth (e.g., a sealing junction or a transfer section), the dentdefining a region with a large gap between the substrates. As a result,an increase in the seal pattern width can itself be suppressed. Byemploying such a dent together with the aforementionedlight-transmitting portion, it becomes possible to obtain both effects.

Other features, elements, processes, steps, characteristics andadvantages of the present invention will become more apparent from thefollowing detailed description of preferred embodiments of the presentinvention with reference to the attached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A, 1B, 1C, and 1D are schematic illustrations showing thestructure of a sealing junction in a liquid crystal display panelaccording to an embodiment of the present invention.

FIG. 2 is a schematic illustration for describing a seal drawing processfor a CF mother substrate 20 from which six color filter substrates areobtained.

FIGS. 3A and 3B are schematic illustrations showing the structure of aseal at a corner portion of a liquid crystal display panel according toan embodiment of the present invention. FIG. 3A is a plan view, and FIG.3B is a cross-sectional view taken along line 3B-3B′ in FIG. 3A.

FIG. 4 is a plan view showing a typical liquid crystal display panel.

FIGS. 5A to 5C are schematic illustrations showing an exemplarystructure of a light shielding layer in the case where alight-transmitting portion is provided along a side on which no signalline terminal section is provided. FIG. 5A is a plan view; FIG. 5B is across-sectional view taken along line 5B-5B′ in FIG. 5A; and FIG. 5C isa cross-sectional view taken along line 5C-5C′ in FIG. 5A.

FIGS. 6A to 6C are schematic illustrations showing another exemplarystructure of a light shielding layer in the case where alight-transmitting portion is provided along a side on which no signalline terminal section is provided. FIG. 6A is a plan view; FIG. 6B is across-sectional view taken along line 6B-6B′ in FIG. 6A; and FIG. 6C isa cross-sectional view taken along line 6C-6C′ in FIG. 6A.

FIGS. 7A to 7C are schematic illustrations showing still anotherexemplary structure of a light shielding layer in the case where alight-transmitting portion is provided along a side on which no signalline terminal section is provided. FIG. 7A is a plan view; FIG. 7B is across-sectional view taken along line 7B-7B′ in FIG. 7A; and FIG. 7C isa cross-sectional view taken along line 7C-7C′ in FIG. 7A.

FIGS. 8A to 8D are schematic illustrations showing an exemplarystructure of a light shielding layer in the case where alight-transmitting portion is provided in a region corresponding to agate bus line terminal section GB1 along a shorter side SE1 of a liquidcrystal display panel. FIG. 8A is a plan view; FIG. 8B is across-sectional view taken along line 8B-8B′ in FIG. 8A; FIG. 8C is across-sectional view taken along line 8C-8C′ in FIG. 8A; and FIG. 8D isa cross-sectional view taken along line 8D-8D′ in FIG. 8A.

FIGS. 9A to 9D are schematic illustrations showing another exemplarystructure of a light shielding layer in the case where alight-transmitting portion is provided in a region corresponding to agate bus line terminal section GB1 along a shorter side SE1 of a liquidcrystal display panel. FIG. 9A is a plan view; FIG. 9B is across-sectional view taken along line 9B-9B′ in FIG. 9A; FIG. 9C is across-sectional view taken along line 9C-9C′ in FIG. 9A; and FIG. 9D isa cross-sectional view taken along line 9D-9D′ in FIG. 9A.

FIGS. 10A to 10C are schematic illustrations showing still anotherexemplary structure of a light shielding layer in the case where alight-transmitting portion is provided in a region corresponding to agate bus line terminal section GB1 along a shorter side SE1 of a liquidcrystal display panel. FIG. 10A is a plan view; FIG. 10B is across-sectional view taken along line 10B-10B′ in FIG. 10A; FIG. 10C isa cross-sectional view taken along line 10C-10C′ in FIG. 10A.

FIGS. 11A to 11D are schematic illustrations showing an exemplarystructure of a light shielding layer in the case where alight-transmitting portion is provided in a region corresponding to asource bus line terminal section SB1 along a longer side LE1 of a liquidcrystal display panel. FIG. 11A is a plan view; FIG. 11B is across-sectional view taken along line 11B-11B′ in FIG. 11A; FIG. 11C isa cross-sectional view taken along line 11C-11C′ in FIG. 11A; and FIG.11D is a cross-sectional view taken along line 11D-11D′ in FIG. 11A.

FIGS. 12A to 12D are schematic illustrations showing another exemplarystructure of a light shielding layer in the case where alight-transmitting portion is provided in a region corresponding to asource bus line terminal section SB1 along a longer side LE1 of a liquidcrystal display panel. FIG. 12A is a plan view; FIG. 12B is across-sectional view taken along line 12B-12B′ in FIG. 12A; FIG. 12C isa cross-sectional view taken along line 12C-12C′ in FIG. 12A; and FIG.12D is a cross-sectional view taken along line 12D-12D′ in FIG. 12A.

FIGS. 13A to 13C are schematic illustrations showing still anotherexemplary structure of a light shielding layer in the case where alight-transmitting portion is provided in a region corresponding to asource bus line terminal section SB1 along a longer side LE1 of a liquidcrystal display panel. FIG. 13A is a plan view; FIG. 13B is across-sectional view taken along line 13B-13B′ in FIG. 13A; FIG. 13C isa cross-sectional view taken along line 13C-13C′ in FIG. 13A.

FIG. 14 is a schematic illustration showing a sealing portion 32 and alight shielding layer 22 including a recess 22 a in a liquid crystaldisplay panel according to an embodiment of the present invention.

FIGS. 15A and 15B are schematic plan views for describing acommonly-employed liquid crystal display panel arrangement.

FIGS. 16A, 16B, 16C, and 16D are schematic plan views showing thestructure of a conventional common transfer section.

FIGS. 17A and 17B are schematic illustrations each showing the structureof a common transfer section in a liquid crystal display panel accordingto an embodiment of the present invention.

FIGS. 18A, 18B, 18C, and 18D are schematic illustrations each showingthe structure of a common transfer section in a liquid crystal displaypanel according to an embodiment of the present invention.

FIGS. 19A, 19B, 19C, and 19D are schematic illustrations each showingthe structure of a common transfer section in a liquid crystal displaypanel according to another embodiment of the present invention.

FIG. 20 is a graph showing a relationship between the thickness of aresin layer 61 (depth of a throughhole 61 a) and the effect of reducingthe width of the sealing portion 32.

FIG. 21 is a schematic illustration showing the characteristics of aseal pattern used in a one drop filling technique.

FIGS. 22A and 22B are enlarged views showing the neighborhood of asealing junction. FIG. 22A is a plan view, and FIG. 22B is across-sectional view.

FIG. 23 is a schematic illustration showing an example of a conventionalseal pattern.

FIG. 24 is a schematic illustration showing another example of aconventional seal pattern.

FIGS. 25A and 25B are schematic illustrations for describing a problemof conventional seal patterns.

FIGS. 26A and 26B are schematic illustrations for describing anotherproblem of conventional seal patterns.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Hereinafter, a liquid crystal display panel according to an embodimentof the present invention and a method for producing the same will bedescribed, with reference to the accompanying drawings.

As shown in FIGS. 1A and 1B, a liquid crystal display panel according toan embodiment of the present invention includes: a TFT substrate 10, acolor filter substrate 20, a liquid crystal layer 40 provided betweenthe TFT substrate 10 and the color filter substrate 20, and a sealingportion 32 surrounding the liquid crystal layer 40. The liquid crystaldisplay panel has a display region and a non-display region surroundingthe display region. The color filter substrate 20 has a first lightshielding layer 22A, which is provided within the non-display region, atan end closer to the display region. The first light shielding layer 22Ahas a recess (light-transmitting portion) 22 a provided near the outerboundary. The width of the sealing portion 32 is allowed to become widerat the recess 22 a of the light shielding layer 22A. Granted that therecess 22 a of the light shielding layer 22A has a sufficient width andlength, if a junction 32 b is formed in the recess 22 a, the junction 32b will not overlap the light shielding layer 22A even when the junction32 b has an increased width. Therefore, as shown in FIG. 1B, the sealantcan be sufficiently cured even if UV irradiation is performed from therear face side of the color filter substrate 20.

Note that the sealant is not limited to a UV curable resin, but may be aresin which is cured with light of any other wavelength (e.g., visiblelight), and various photocurable resins can be suitable. As used herein,a “photocurable resin” refers to any resin which undergoes curingreaction in response to irradiation of light of a predeterminedwavelength, and includes any resin for which thermosetting can befurther performed after photocuring. With such auxiliary use ofthermosetting, the physical characteristics of the cured matter (e.g.,hardness and elastic modulus) are generally improved. Furthermore,particles (filler) for conferring a scattering ability to the sealantmay be mixed to the sealant together with the photocurable resin. Asealant in which particles are dispersed will cause scattering ordiffuse reflection of light, thus allowing light to be permeated througha broader region of the sealant.

The light shielding layer 22A of the color filter substrate 20 shown inFIG. 1A is illustrated as having a single recess 22 a which extends overthe entire length of the junction 32 b. Instead of such a recess 22 a,any other recess may be used as long as the recess allows the sealant tobe sufficiently irradiated with light. For example, as exemplified by alight shielding layer 22B shown in FIG. 1C, a plurality of minuterecesses 22 b may be provided in stripes. Alternatively, as exemplifiedby a light shielding layer 22C shown in FIG. 1D, a plurality of minuteopenings (holes) 22 c may be provided. Depending on the recess(es) orthe opening(s), the light-transmitting portion for allowing the sealantto receive light irradiation does not need to be formed with a constantwidth, but may have a changing width so as to accommodate the expandingwidth of the junction 32 as necessary. In the case where the recesses 22b or openings 22 c as shown in FIG. 1C or 1D are provided, it is moredifficult for the sealant to receive light irradiation than in the caseof employing the recess 22 a shown in FIG. 1A. Therefore, in this case,it would be preferable to employ a light irradiation apparatus of a typewhich not only allows light to be incident to the substrate at a rightangle but can also introduce a certain irradiation angle by means of areflector or the like, or employ a sealant which has scatteringabilities (diffuse reflection properties).

In the final liquid crystal display panel, the display quality may bedeteriorated due to the light which has passed through the recess 22 aprovided in the light shielding layer 22A. Therefore, it is preferableto provide a further light shielding layer in a position opposing therecess 22 a. Although it might be possible to attach a light shieldingtape or the like on the outside (i.e., the side closer to the viewer) ofthe color filter substrate 20, such is not preferable because the numberof production steps will be increased, positioning problems may occur,and a level difference may occur when the liquid crystal display panelis mounted in a housing. Therefore, as will be later described inspecific examples, it is preferable to provide a light shielding layerat a corresponding position on the TFT substrate 10. In this case, byforming a light shielding layer by using the same conductive layer asthat of the source bus line and/or gate bus line provided on the TFTsubstrate, it becomes possible to form the light shielding layer withoutincreasing the number of steps.

By adopting the above-described structure, it becomes possible to allowthe sealant to be sufficiently cured even if a sealing junction isformed within the liquid crystal display panel, without complicating theproduction steps. It is also possible to effectively prevent leakage oflight from a light-transmitting portion which is provided in a lightshielding layer of a color filter substrate. Since light irradiation isperformed from the color filter substrate side, the light with which theTFTs are irradiated is attenuated at least when transmitted through thecolor filters, so that damage due to light irradiation for the TFTs canbe reduced. In the case where it is possible to obtain a sufficientattenuation with the color filters alone, it is unnecessary to employ amask for protecting the TFTs from light irradiation, thus furtherimproving the production efficiency.

Next, with reference to FIG. 2, a liquid crystal display panel accordingto an embodiment of the present invention production method will bedescribed.

FIG. 2 is a schematic illustration for describing a seal drawing processfor a CF mother substrate 20 from which six color filte substrates areobtained. One advantage of a liquid crystal display panel according toan embodiment of the present invention production method is that, aswill be described below, use of a plurality of junctions makes itpossible to obtain a large-sized liquid crystal display panel by using adispenser which in itself has a relatively narrow movable range. Anotheradvantage is that, by providing two or more junctions within the liquidcrystal display panel, an increased freedom is obtained with respect tothe drawing order of the seal pattern, and/or it is possible tosimultaneously draw the seal pattern by employing a plurality ofdispensers, whereby the tact time of the seal drawing process can bereduced.

For one of the six color filter substrates 20 (A1 to A3 and B1 to B3) tobe derived from the CF mother substrate 20 (e.g., A1 in FIG. 2),application of a sealant may be begun from a point S1, for example.Thus, the point S1 serves as a start point of the seal pattern. Thepoint S1 is chosen in the neighborhood of the recess 22 a of the colorfilter substrate 20 (note that FIG. 2 schematically illustrates therecesses 22 a only). After seal drawing is begun from the point S1, thesealant is applied along the outer periphery of the light shieldinglayer 22 of the color filter substrate 20 (along the solid line in FIG.2), and the sealant application is ended in the neighborhood (point S2)of another recess 22 a. The point S2 serves as an end point of the sealpattern.

Thereafter, with respect to the color filter substrate A1, sealantapplication is again begun from the start point S1, and, along thebroken line in FIG. 2, seal drawing is performed until reaching the endpoint S2. Thus, a sealing portion which surrounds the display region canbe formed.

Thus, by adopting a constitution in which a plurality of junctions areprovided, it becomes unnecessary to encompass the entire range from thestart point S1 to the end point S1 in a single drawing. Therefore, sealdrawing is enabled even if the nozzle of the dispenser (and/or themother substrate) can only move in a relatively narrow movable range. Inthe case where a sufficient movable range is available, it would offcourse be possible to begin seal drawing from e.g. the start point S1,apply the sealant along the outer periphery of the light shielding layer22 of the color filter substrate 20, past the point S2 and then back tothe start point S1, thus forming a junction at the point S1. In thiscase, only one junction will be formed at the point S1.

Furthermore, according to the production method of the embodiment of thepresent invention, it is not necessary to complete the entire sealingportion 32 on one of the six color filter substrates (A1 to A3 and B1 toB3) before moving onto another color filter substrate. For example, aseal pattern corresponding to the solid line may be simultaneously drawnon each of the color filter substrates A1 to A3; and subsequently to orconcurrently with this, a seal pattern corresponding to the solid linemay be simultaneously drawn on each of the color filter substrates B1 toB3. Thereafter, a seal pattern corresponding to the broken line may besimultaneously drawn on each of the color filter substrates A1 to A3;and subsequently to or concurrently with this, a seal patterncorresponding to the broken line may be simultaneously drawn on each ofthe color filter substrates B1 to B3.

Although this example illustrates the case where the recesses 22 a areprovided on the shorter sides of the substrate having a rectangularshape, it would also be possible to provide a recess(es) on a longerside(s) of the substrate. Furthermore, it would also be possible toprovide recesses on both a shorter side(s) and a longer side(s), thusforming three or more junctions. The positioning of the recesses 22 a(i.e., the light-transmitting portions) may be adjusted according to themovable range of the dispenser, the size of the mother substrate, andthe positioning of the panels in the mother substrate. Without beinglimited to the recesses 22 a, it may be possible to employ recesses 22 bor openings 22 c as shown in FIG. 1C or 1D, or any mixture thereof.Thus, there are no limitations as to the shape of the recesses oropenings as long as the sealant is sufficiently irradiated with light.However, as will be described later, it would be preferable to optimizethe shapes and positioning of the recesses or openings in order torealize efficient light shielding with the light shielding layerprovided on the TFT substrate.

Although the above example illustrates a case where seal drawing isperformed for the CF mother substrate 20, it would also be possible todraw a seal pattern in a corresponding region of the TFT mothersubstrate 10. In other words, a seal pattern may drawn so that theposition at which the sealing portion 32 will be formed when the colorfilter substrate 20 and the TFT substrate 10 are attached togethersatisfies the aforementioned relationship with respect to thelight-transmitting portion(s) 22 (recesses 22 a) in the light shieldinglayer 22 of the color filter substrate.

In the liquid crystal display panel production method of the presentembodiment, the junction of the sealant is formed inside the liquidcrystal display panel, and therefore, no sealing portion exists outsidethe liquid crystal display panel, unlike in Japanese Laid-Open PatentPublication No. 2002-122870. As a result, cutting failures are preventedwhen the TFT mother substrate 10 and the CF mother substrate 20 are cutinto pieces corresponding to liquid crystal panels. Even in the casewhere signal line terminal sections are to be provided on three or moresides of the liquid crystal panel, problems such as inability to removea fragment of the color filter substrate are prevented.

Note that light-transmitting portions such as the recesses 22 arepreferably provided not only at junctions but also at corner portions,as shown in FIGS. 3A and 3B. By providing a recess 22 d in a cornerportion of a light shielding layer 22D, it becomes possible to prevent asealant 32 a′ which has become thick at the corner portion fromoverlapping the light shielding layer 22D, thus allowing the sealant tobe sufficiently cured.

Although a junction might well be formed at such a corner portion, it ispreferable to form any junction along a side (excluding the corners) ofthe substrate, from the standpoint of facilitating examination of thejunction. A junction which is formed along a side can be tested forsoundness by detecting the width of the sealing portion by using anoptical technique. In other words, failures such as incompleteness(i.e., disruption) or excessively thin width of a junction can be easilydetected if the junction is formed along a side.

Next, with reference to FIGS. 4 to 13, the structure of a liquid crystaldisplay panel according to an embodiment of the present invention willbe described in more detail.

FIG. 4 is a plan view showing a typical liquid crystal display panel.The liquid crystal display panel includes: a TFT substrate 10′; a colorfilter substrate 20; and a sealing portion 32 for realizing adhesiveattachment between the TFT substrate 10′ and the color filter substrate20. The TFT substrate 10′ has two longer sides LE1 and LE2, as well astwo shorter sides SE1 and SE2. In the example shown, the longer side LE1and the shorter side SE1 extend outside the color filter substrate 20; asource bus line terminal section SB1 is provided on the longer side LE1;and a gate bus line terminal section GB1 is provided on the shorter sideSE1. Therefore, at these signal bus line terminal sections SB1 and GB1,the sealing portion 32 and a light shielding portion (not shown) of thecolor filter substrate 20 overlap the signal bus lines. Therefore, inthe case where the TFT substrate needs to have a light shielding layercorresponding to the light-transmitting portions (e.g., recesses) whichare provided in the light shielding layer of the color filter substrate20, the preferable structure of such light shielding layer would varydepending on the positions of the lines (e.g., the source bus lines orthe gate bus lines).

FIG. 4 illustrates an example where signal line terminal sections areprovided on two sides of the substrate. Alternatively, the presentinvention is also applicable to a structure featuring signal lineterminal sections provided on three sides (e.g., gate bus line terminalsections being provided on the two shorter sides), or a structurefeaturing signal line terminal sections provided on four sides (i.e.,gate bus line terminal sections being provided on two sides and sourcebus line terminal sections being provided on the other two sides).

First, with reference to FIGS. 5A, 5B, 5C, 6A, 6B, 6C, 7A, 7B, and 7C,an exemplary structure of a light shielding layer in the case where alight-transmitting portion is provided along sides (SE2 or LE2) on whichno signal line terminal section is provided will be described. FIGS. 5Ato 5C are illustrations showing an exemplary structure of a lightshielding layer in the case where a light-transmitting portion isprovided along a side on which no signal line terminal section isprovided. FIG. 5A is a plan view; FIG. 5B is a cross-sectional viewtaken along line 5B-5B′ in FIG. 5A; and FIG. 5C is a cross-sectionalview taken along line 5C-5C′ in FIG. 5A. FIGS. 6A to 6C areillustrations showing another exemplary structure. FIG. 6A is a planview; FIG. 6B is a cross-sectional view taken along line 6B-6B′ in FIG.6A; and FIG. 6C is a cross-sectional view taken along line 6C-6C′ inFIG. 6A. FIGS. 7A to 7C are illustrations showing still anotherexemplary structure. FIG. 7A is a plan view; FIG. 7B is across-sectional view taken along line 7B-7B′ in FIG. 7A; and FIG. 7C isa cross-sectional view taken along line 7C-7C′ in FIG. 7A.

FIGS. 5A to 5C illustrate a case where a recess 22 a is provided at aposition where a sealing junction 32 b is to be formed. FIGS. 6A to 6Cillustrate a case where a plurality of recesses 22 b are provided atsuch a position. FIGS. 7A to 7C illustrate a case where a plurality ofrecesses 22 b′ and a plurality of openings 22 c′ are provided at such aposition. In either case, no gate bus line terminal section or no sourcebus line terminal section exists in the regions of the TFT substrate 10corresponding to the light-transmitting portions (22 a, 22 b, 22 b′, 22c′) in the light shielding layer 22 of the color filter substrate.Therefore, a light shielding layer 12 a may be provided in any necessaryregions. The TFT substrate 10 includes a glass substrate 11, gate buslines (not shown) formed on the glass substrate 11, a gate insulatingfilm 13 covering the gate bus lines, source bus lines (not shown) formedon the gate insulating film, and an insulative protection film 15covering the source bus lines. When patterning the conductive layercomposing the gate bus lines, the patterning may be performed in such amanner as to leave the light shielding layer 12 a intact, thus allowingthe light shielding layer 12 a to be formed through the same process offorming the gate bus lines. By adopting such a constitution, it becomespossible to form the light shielding layer 12 a on the TFT substrate 10without increasing the number of production steps.

On the shorter side SE2, main lines of storage capacitor line forsupplying predetermined signals for storage capacitors which areprovided for the respective pixels, and reserve lines for correctingelectrical connections of any signal line that has experienced a break.Such main or reserve lines are relatively thick, and therefore can beutilized as a light shielding layer. In general, main lines and reservelines of storage capacitor line are composed of the same conductivelayer that composes the gate bus lines, and are formed by the sameprocess of forming the gate bus lines. Thus, since a high design freedomfor forming the light shielding layer exists at the shorter sides of theliquid crystal display panel, it is preferable to form any sealingjunction on a shorter side.

Specifically, the TFT substrate can be fabricated through the followingprocess.

On the glass substrate 11, a Ti/Al/TiN stacked film is grown by using asputtering apparatus. Through etching processes such as aphotolithography process and dry etching, the gate bus lines and thegate electrodes are formed, and the light shielding layer 12 a is alsoconcurrently formed. For example, in the case where storage capacitorline is to be formed concurrently with the gate bus lines and the like,the main lines of storage capacitor line may be provided at the shorterside SE2, thus making it possible to utilize the main lines of storagecapacitor line as the light shielding layer 12 a.

Next, upon these layers, the gate insulating film 13 of silicon nitride(SiNx) or the like is grown by a plasma CVD technique. Thereafter,active elements such as TFTs are formed. Furthermore, a Ti/Al/TiNstacked film is grown by using a sputtering apparatus, and throughetching processes such as a photolithography process and dry etching,the source bus lines and the drain electrodes are formed.

Next, an insulative protection film 15 such as a transparent resin isformed by a spin coating technique or the like. In the insulativeprotection film 15, contact holes for establishing contact between thepixel electrodes to be formed thereupon and the drain electrodes aremade, and throughholes for forming storage capacitors are made. Upon theinsulative protection film 15, transparent electrodes (e.g., ITO) aregrown by sputtering, and the pixel electrodes are formed through aphotolithography process and an etching process.

The color filter substrate may be fabricated as follows, for example.

By a dry film technique, a spin coating technique, an ink jet techniqueor the like, a light shielding layer is formed in regions of a glasssubstrate 21 corresponding to color filters of RGB (red, green, blue)which correspond to the pixels of the TFT substrate, as well as othernecessary regions. Since the light shielding layer is formed by using ablack photocurable resin, light-transmitting portions (recesses and/oropenings) can be formed through the same process during patterning.

Next, with reference to FIGS. 8A, 8B, 8C, 8D, 9A, 9B, 9C, 9D, 10A, 10B,and 10C, an exemplary structure of a light shielding layer in the casewhere light-transmitting portions are to be provided in a regioncorresponding to the gate bus line terminal section GB1 along theshorter side SE1 will be described. FIGS. 8A to 8C are illustrationsshowing an exemplary structure of a light shielding layer in the casewhere light-transmitting portions are to be provided in a regioncorresponding to the gate bus line terminal section GB1 along theshorter side SE1. FIG. 8A is a plan view; FIG. 8B is a cross-sectionalview taken along line 8B-8B′ in FIG. 8A; FIG. 8C is a cross-sectionalview taken along line 8C-8C′ in FIG. 8A; and FIG. 8D is across-sectional view taken along line 8D-8D′ in FIG. 8A. FIGS. 9A to 9Care illustrations showing another exemplary structure. FIG. 9A is a planview; FIG. 9B is a cross-sectional view taken along line 9B-9B′ in FIG.9A; FIG. 9C is a cross-sectional view taken along line 9C-9C′ in FIG.9A; and FIG. 9D is a cross-sectional view taken along line 9D-9D′ inFIG. 9A. FIGS. 10A to 10C are illustrations showing still anotherexemplary structure. FIG. 10A is a plan view; FIG. 10B is across-sectional view taken along line 10B-10B′ in FIG. 10A; and FIG. 10Cis a cross-sectional view taken along line 10C-10C′ in FIG. 10A.

Gate bus lines 12 b are formed on the glass substrate 11 of the TFTsubstrate 10. The gate bus lines 12 b function as a light shieldinglayer. However, in the case where a recess 22 a is formed as shown inFIG. 8A, light will pass through between the gate bus lines 12 b.Therefore, a conductive layer 14 a which is in the same layer level asthe source bus lines is used to form a plurality of light shieldingportions 14 a for ensuring light shielding in the interspaces betweenthe gate bus lines 12 b, as shown in FIG. 8D. It might be possible toconstruct the light shielding portions 14 a in the form of a singlelight shielding layer which overlaps the gate bus lines 12 b and anyinterspaces therebetween. However, in the case where such a lightshielding layer overlaps with the gate bus lines via the gate insulatingfilm 13, there may be a possible problem of insufficient insulation dueto foreign matter or the like, and in some cases, short-circuiting mayoccur between the gate bus lines. Therefore, from the standpoint ofproduction yield, it would be preferable to form discrete lightshielding portions 14 a corresponding to the interspaces between thegate bus lines 12 b, so that there is no overlap between the resultantlight shielding layer and the gate bus lines 12 b.

As shown in FIG. 9A, a plurality of recesses 22 b may be provided so asto oppose the gate bus lines 12 b. In this case, sufficient lightshielding can be realized with the gate bus lines 12 b alone, and thusan advantage of a simplified construction is provided.

As shown in FIG. 10A, a plurality of recesses 22 b′ and a plurality ofopenings 22 c′ may be provided such that the openings 22 c′ oppose thegate bus lines 12 b, and a light shielding layer 14 a may be provided soas to correspond to the recesses 22 b′. As a result, light passingthrough the light-transmitting portions can be shielded.

Next, with reference to FIGS. 11A, 11B, 11C, 11D, 12A, 12B, 12C, 12D,13A, 13B, and 13C, an exemplary structure of a light shielding layer inthe case where light-transmitting portions are to be provided in aregion corresponding to the source bus line terminal section SB1 alongthe longer side LE1 will be described.

FIGS. 11A to 11C are illustrations showing an exemplary structure of alight shielding layer in the case where light-transmitting portions areto be provided in a region corresponding to the source bus line terminalsection SB1 along the longer side LE1. FIG. 11A is a plan view; FIG. 11Bis a cross-sectional view taken along line 11B-11B′ in FIG. 11A; FIG.11C is a cross-sectional view taken along line 11C-11C′ in FIG. 11A; andFIG. 11D is a cross-sectional view taken along line 11D-11D′ in FIG.11A. FIGS. 12A to 12C are illustrations showing another exemplarystructure. FIG. 12A is a plan view; FIG. 12B is a cross-sectional viewtaken along line 12B-12B′ in FIG. 12A; FIG. 12C is a cross-sectionalview taken along line 12C-12C′ in FIG. 12A; and FIG. 12D is across-sectional view taken along line 12D-12D′ in FIG. 12A. FIGS. 13A to13C are illustrations showing still another exemplary structure. FIG.13A is a plan view; FIG. 13B is a cross-sectional view taken along line13B-13B′ in FIG. 13A; and FIG. 13C is a cross-sectional view taken alongline 13C-13C′ in FIG. 13A.

Source bus lines 14 b are formed on the glass substrate 11 of the TFTsubstrate 10. The source bus lines 14 b function as a light shieldinglayer. However, in the case where a recess 22 a is formed as shown inFIG. 11A, light will pass through between the source bus lines 14 b.Therefore, a conductive layer 12 a which is in the same layer level asthe gate bus lines 12 b is used to form a plurality of light shieldingportions 12 a for ensuring light shielding in the interspaces betweenthe source bus lines 14 b, as shown in FIG. 11D. It might be possible toconstruct the light shielding portions 12 a in the form of a singlelight shielding layer which overlaps the source bus lines 14 b and anyinterspaces therebetween. However, for the aforementioned reason, fromthe standpoint of production yield, it would be preferable to formdiscrete light shielding portions 12 a corresponding to the interspacesbetween the source bus lines 14 b. Although FIG. 11D illustrates anexample where light shielding portions 12 a are formed under the gateinsulating film 13, and the source bus lines 14 b are formed on a gateinsulating film, such is not the only possible structure. For example,depending on the formation process of the TFTs, there may be cases wherethe source bus lines in the active area (display region) are connectedto gate metals (i.e., conductive layers composing the gate bus lines)before being connected to the source terminal portion in the frameregion, thus realizing the line in the source terminal portion by meansof the gate metals. In this case, the aforementioned effects will stillbe obtained, although the stacking relationship (i.e., which one liesabove the other) between the lines 14 b and the light shielding portions12 a relative to the gate insulating film 13 will be reversed from thatshown in FIG. 11D. The same is also true of any other embodiment.

As shown in FIG. 12A, a plurality of recesses 22 b may be provided so asto oppose the source bus lines 14 b. In this case, sufficient lightshielding can be realized with the source bus lines 14 b alone, and thusan advantage of a simplified construction is provided.

As shown in FIG. 13A, a plurality of recesses 22 b′ and a plurality ofopenings 22 c′ may be provided such that the openings 22 c′ oppose thesource bus lines 14 b, and a light shielding layer 12 a may be providedso as to correspond to the recesses 22 b′. As a result, light passingthrough the light-transmitting portions can be shielded.

In the case where a 17″ SXGA type liquid crystal display panel is to beproduced by using a liquid crystal display panel according to anembodiment of the present invention production method, for example, thefollowing structure may be preferable.

FIG. 14 is a schematic illustration showing a sealing portion 32 and alight shielding layer 22 including a recess 22 a in a 17″ SXGA typeliquid crystal display panel.

As shown in FIG. 14, the structure having a recess 22 a as shown in FIG.1 is adopted in this example. The liquid crystal display panel has thesame structure as that shown in FIG. 4, with the recess 22 a beingprovided on the shorter side SE2. Main lines of storage capacitor lineprovided on the TFT substrate are utilized for light shielding withinthe recess 22 a.

The interspace Ws between the perimeter of the light shielding layer 22Aand the cut line is 2.3 mm. The recess 22 a has a “depth” D of 0.3 mmand a length W of 10.0 mm. The width of the light shielding layer 22A(in the region other than the recess 22 a) is about 3 mm. The reason forsuch sizing is described below.

It was found that, when a seal width (i.e., the width of the mainstretch 32 a) of 1.2 mm was set on the particular dispenser used,variations of ±0.3 mm would result. The positioning accuracy of thenozzle of the dispenser was ±0.15 mm. A margin of ±about 0.2 mm wasdetermined based on the cutting accuracy of the mother substrate.Therefore, the interspace Ws from the perimeter of the light shieldinglayer 22A to the cut line must be 2 mm or more, based on 1.2 mm+0.3mm+(0.15 mm×2)+0.2 mm. In this particular example, Ws was set at 2.3 mm.

The width of the sealing junction 32 b had a maximum value Smax of about2.1 mm. To this, the positioning accuracy (0.15 mm×2) of the nozzle wasadded, and further in view of the cutting margin of 0.2 mm, theinterspace from the perimeter of the light shielding layer 22A to thecut line at the recess 22 a was set to be 2.6 mm. In other words, the“depth” D of the recess 22 a was set at 0.3 mm.

Moreover, since any corner portion would become thicker than the mainstretch by 0.1 mm to 0.15 mm, the light shielding layer was recessed bya “depth” of 0.15 mm at every corner portion, and a seal pattern wasdrawn so that the minimum interspace between the perimeter of the lightshielding layer and the cut line was equal to 2.45 mm (see FIG. 3A).

In the fabrication of the liquid crystal display panel, as has beendescribed with reference to FIG. 2, a seal drawing was performed for theCF mother substrate 20. Thereafter, by a known method, a liquid crystalmaterial was dripped onto the CF mother substrate 20 by a one dropfilling technique. After the TFT mother substrate 10 was attachedthereto in a predetermined place, UV irradiation was performed from thecolor filter substrate side to cure the sealant. The sealant curing wassupplemented by, after performing UV irradiation at several joule/cm²,also performing thermosetting at 120° C. for 1 hour.

The resultant liquid crystal display panel experienced no cuttingfailures during cutting, and no deterioration in reliability wasobserved, e.g., lowering of the voltage retention rate due to curingfailure of the sealant, or orientation defects. Moreover, no degradationin display quality due to light leakage through the recess was observed.

By adopting the procedure which involves dripping a liquid crystalmaterial onto the CF mother substrate 20, attaching the TFT mothersubstrate 10, and performing light irradiation from below (i.e., fromthe CF mother substrate 20 side), it becomes possible to perform all thesteps from the seal drawing to the light irradiation while maintainingthe CF mother substrate 20 so as to be on the lower side of the displaypanel (with the surface bearing the color filters facing up), thusmaking it possible to use simple apparatuses and processes.

With the patterns shown in FIGS. 1C and 1D, when light irradiation forcuring the sealant is performed only from the side of one of thesubstrates, the irradiation time required for achieving sufficientcuring may be prolonged (occasionally threefold or more) depending onthe area ratio of the light-transmitting portions.

On the other hand, the above-described structure featuring a pluralityof recesses or openings provided in the light shielding layer of the CFsubstrate, where source bus lines and/or gate bus lines, etc., areutilized as a light shielding layer of the TFT substrate for selectivelyshielding the light passing through the recesses or openings, makes itpossible to perform light irradiation for the sealant also from the TFTsubstrate side because light is allowed to pass through the interspacesbetween the source bus lines and/or the gate bus lines. Thus, it becomespossible to perform light irradiation for the sealant from the sides ofboth substrates, by ensuring that the light shielding layer on the TFTsubstrate side includes light-transmitting portions corresponding to theinterspaces between, or the peripheries around, the plurality ofrecesses or openings in the light shielding layer of the CF substrate.As a result, the irradiation time required for sealant curing can bereduced.

As a method for performing light irradiation from both sides of thedisplay panel, light sources may simply be provided above and below thedisplay panel, respectively. Alternatively, a mechanism for reversingthe display panel may be provided for the apparatus used; in this case,the light irradiation time will be about twice the minimum irradiationtime required in the case of performing irradiation from both sides ofthe display panel, but will still be shorter than the irradiation timerequired in the case of performing irradiation from only one side of thedisplay panel. Some sealing materials are capable of being photocuredover a distance of about several tens of μm from the edge of eachopening toward the light shielding portion, and therefore it ispreferable to use such materials.

The pattern of recesses or openings is not limited to stripes, but mayalso be a mesh pattern as shown in FIG. 1D. Although FIG. 1D illustratesa mesh array consisting of circular openings, the shape of the openingsis not limited to circles, but may be rectangular, for example. A partof the pattern may be rounded or include a bent. In particular, in thecase where light shielding is realized by the signal lines on the TFTsubstrate, it is likely that the shapes of the signal lines are subjectto design constraints. Therefore, it would be preferable to adapt theopening pattern to the line pattern.

As light irradiation apparatuses for use in seal curing, there are knownapparatuses which employ a reflector and the like to enable lightirradiation in not only the normal direction of the display panel, butalso in an oblique direction. By employing such an apparatus which iscapable of performing light irradiation also from an oblique direction,it becomes possible to attain sufficient curing of the sealant even ifthere is a slight overlap between the light shielding layer of the CFsubstrate and the light shielding layer of the TFT substrate. Forexample, it has been experimentally confirmed that, even if there is anoverlap which is about as large as the gap between the substrates, theresultant liquid crystal display panel exhibits no significantdifference in reliability after being irradiated under the sameirradiation conditions (irradiation intensity and irradiation time) asthose under the case where there is no overlap.

Next, a problem that may occur in a transfer section (i.e., a section atwhich an electrical potential of an electrode on one of the substratesis to be transferred to an electrode on the other substrate whichincludes a terminal for providing connection to the outside) will bedescribed. Hereinafter, an example problem will be illustrated withrespect to a common transfer section, which is a type of transfersection which composes a path for electrically connecting a counterelectrode (which is also referred to as a “common electrode”) on a CFsubstrate to a terminal on the TFT substrate.

FIGS. 15A and 15B schematically show a commonly-employed TFT liquidcrystal display panel arrangement. FIG. 15B shows an equivalent circuitof a single pixel of a TFT liquid crystal display panel.

As shown in FIG. 15B, by driving a TFT 64 with a gate bus line 63, witha source bus line 62 being connected to the TFT 64, a predeterminedsignal voltage is supplied to a pixel electrode 65. The pixel electrode65 opposes a common electrode 66 with a liquid crystal layer 40interposed therebetween, thus constituting a liquid crystal capacitance(capacitor). When a signal voltage is applied across the liquid crystallayer 40 via the TFT 64, the optical characteristics of the liquidcrystal layer 40 are changed, whereby the display panel functions as adisplay device.

The common electrode 66, which is formed on the surface of the CFsubstrate 20 facing the liquid crystal layer 40, has its electricalpotential transferred to the TFT substrate 10′ side via a commontransfer section 60, and thus is connected to a common electrodeterminal 66 a. As shown in FIG. 15A, source bus lines 62 a and gate busline terminals 63 a are provided in the non-display region of the TFTsubstrate 10′. Usually, the common electrode terminals 66 a and thesource bus lines 62 a are to be provided on the same side (i.e., one ofthe four sides) of the display panel.

As a transfer material composing the common transfer section, a transfermaterial containing a photocurable resin and conductive particles isused. The conductive particles may be, for example, metal particles orplastic beads having a metal coating thereon, with a grain size of about4 to 10 μm. As the photocurable resin to be contained in the transfermaterial, any photocurable resin similar to those used in a sealant isused.

In the case where a common transfer section is to be formed by using atransfer material containing a photocurable resin, the frame regionwould need to be broad enough to provide a light-transmitting region forallowing the common transfer section to be irradiated with light.Therefore, each common transfer section may be made to at leastpartially overlap with the sealing portion. However, even if each commontransfer section were to be formed within the sealing portion, the widthof the sealing portion would become thicker where the sealing portioncontains the common transfer section, again resulting in the problem ofa large frame region.

This problem will be described with reference to FIGS. 16A to 16D below.Any constituent element which also appears in the foregoing descriptionswill be denoted by like numerals, and their descriptions will be omittedherein.

The common transfer section 60 is provided in the neighborhood of thesealing portion 32, so as to electrically connect a counter electrode(not shown) on a CF substrate (not shown) to a common pad 60 a on theTFT substrate. As shown in FIG. 16D, if the common transfer section 60is provided at a position away from the sealing portion 32, thenon-display region (frame region) must have a broad width. Therefore, asshown in FIGS. 16A to 16C, it is common practice to allow the commontransfer section 60 to at least partially overlap with the sealingportion 32. However, in any of the cases illustrated in FIGS. 16A to16C, the sealant will be pushed out by the common transfer section 60,thus resulting in a portion 32 c (which may also be referred to as a“common transfer sealing portion”) at which the width of the sealpattern is broadened. Thus, there is a problem in that the commontransfer sealing portion 32 c has a broader width than that of the mainstretch 32 a (see, for example, FIG. 1), similarly to theabove-described junction 32 b.

Therefore, according to the present embodiment, light-transmittingportions (recesses or openings) are provided in the light shieldingportion of the substrate from which the light irradiation for curing thecommon transfer sealing portion 32 c is to be performed.

FIGS. 17A and 17B are schematic illustrations each showing the structureof a common transfer section in a liquid crystal display panel accordingto an embodiment of the present invention. FIG. 17A is a plan view; andFIG. 17B is a cross-sectional view taken along line 17B-17B′ in FIG.17A.

The color filter substrate 20 includes a first light shielding layer 22Awhich is provided within the non-display region, at an end closer to thedisplay region. The first light shielding layer 22A includes a recess(light-transmitting portion) 22 a provided near the outer boundary. Thewidth of the sealing portion 32 is allowed to become wider at the recess22 a of the light shielding layer 22A. Granted that the recess 22 a ofthe light shielding layer 22A has a sufficient width and length, if acommon transfer sealing portion 32 c is formed in the recess 22 a, thecommon transfer sealing portion 32 c will not overlap the lightshielding layer 22A even when the common transfer sealing portion 32 chas an increased width. Therefore, as shown in FIG. 17B, the sealant canbe sufficiently cured even if UV irradiation is performed from the rearface side of the color filter substrate 20. So long as the sealant issubjected to sufficient light irradiation, the light-transmittingportion is not limited to the recess 22 a. For example, as in the lightshielding layer 22B shown in FIG. 1C, stripes containing a plurality ofminute recesses 22 b may be provided. Alternatively, as in the lightshielding layer 22C shown in FIG. 1D, a plurality of minute openings(holes) 22 c may be provided, or any other shape may be adopted, as inthe earlier-described embodiments.

Next, an embodiment in which the broadening of the width of the sealingportion is in itself suppressed will be described. In the embodimentdescribed below, a broad-gap region, i.e., a region in which the gapbetween the CF substrate and the TFT substrate is partially increased,is provided within the non-display region of the liquid crystal displaypanel. Any portion where the width of the seal pattern is expected toincrease is formed in this broad-gap region, thus to suppress thebroadening of the seal pattern. The broad-gap region is created byforming a dent on the surface of the CF substrate or the TFT substratefacing the liquid crystal layer. When a transfer material or sealant isapplied to such a dent, spreading of the sealant over the display areais suppressed since the dent constitutes a broad-gap region.

There is a variety of methods for forming a dent on the surface of thesubstrate. For example, in the case where a resin film is to be formedon the TFT substrate, a dent or a throughhole may be formed at apredetermined position in the resin film. Such a resin film may beutilized for forming an interlayer insulating film which is to beprovided between the TFTs or signal lines formed on the TFT substrateand the pixel electrodes, for example. Alternatively, various resinlayers (e.g., colored resin layers) to be formed on the color filtersubstrate may also be utilized.

Hereinafter, an example will be described where a broad-gap region iscreated by utilizing a resin layer which is formed as an interlayerinsulating film on the TFT substrate. While the aforementioned commontransfer sealing portion 32 c will be illustrated as a possible site ofbroadening of the sealing portion, it will be appreciated that the sameprinciple is broadly applicable to any part of the sealing portion atwhich an increase in the width of the seal pattern is expected, e.g.,junctions or corner portions. Furthermore, a broad-gap region may beused in combination of any structure in which a light shielding layerincludes a light-transmitting portion(s) as described in the embodimentsabove.

FIGS. 18A, 18B, 18C, and 18D are schematic illustrations each showingthe structure of a common transfer sealing portion in a liquid crystaldisplay panel according to an embodiment of the present invention. FIGS.18A, 18C, and 18D are plan views; and FIG. 18B is a cross-sectional viewtaken along line 18B-18B′ in FIG. 18A.

As shown in FIG. 18A, a resin layer 61 is provided on the sealingportion 32, with a throughhole 61 a being formed at the portion of theresin layer 61 corresponding to the common transfer section 60. Thethroughhole 61 a defines a broad-gap region. Although an example isdescribed where the throughhole 61 a is sized similarly to the commonpad 60 a, the present embodiment is not limited thereto.

The sealing portion 32 is formed by applying a sealant in such a mannerthat the sealing portion 32 takes a predetermined line width in anyportion where the gap is equal to a gap value which is determined by thedesign of the liquid crystal display panel (i.e., the thickness of theliquid crystal layer). Because of the throughhole 61 a, the gap in theregion where the common transfer sealing portion 32 c is formed isincreased by a distance equal to the film thickness of the resin layer61. Since the sealant which being applied in a linear shape has aconstant cross-sectional area, the seal width will become comparativelysmaller at the throughhole 61 a in the resin layer 61; for example, ifit were not for the common transfer section 60, the line width of theseal will be reduced at the dent (throughhole 61 a) as shown in FIG.18C. When a common transfer substance is applied, the sealant willspread out as dictated by the volume of the common transfer substance,thus resulting in a structure as shown in FIG. 18A.

For example, the common transfer sealing portion 32 c had a maximumwidth of 1100 μm in an experimentation example performed under thefollowing conditions: the resin layer had a film thickness of 2.5 μm;the sealing portion 32 had a width of about 1000 μm; the sealing portionhad a gap of 5.5 μm where the resin layer existed; the throughhole 61 ain the resin layer had a width of 1200 μm; and the target diameter ofthe common transfer section 60 (in the theoretical case where no sealexisted) was 500 μm.

Preferably, the throughhole 61 a in the resin layer 61 of the presentembodiment has a width which is greater than the diameter of the commontransfer section 60 or the maximum value of the width of the mainsealing portion (main stretch). In a similar experimentation where nothroughhole was made in the resin layer, the common transfer sealingportion showed a maximum width of about 1400 μm. Therefore, according tothe present embodiment of the invention, the width of the commontransfer sealing portion 32 c including the common transfer section 60was reduced by 300 μm as compared to the conventional case. The 300 μmreduction in the width of the recess 22 a of the light shielding layerindicates that a further narrowed frame region is made possible than inthe embodiments above.

Furthermore, in another case where the target diameter of the commontransfer section 60 (in the theoretical case where no seal existed) wasset at 400 μm, the common transfer sealing portion 32 c had a maximumline width of about 1000 μm. In this case, since the maximum line widthis equal to the width (1000 μm) of the main sealing portion 32, it ispossible to omit the recess 22 a in the light shielding layer 22A, asexemplified in FIG. 18D.

It is not necessary that the throughhole 61 a in the resin layer 61 beso wide as to encompass the entire width of the sealing portion. Thispoint will be described with reference to FIGS. 19A, 19B, 19C, and 19D.

FIGS. 19A, 19B, 19C, and 19D are schematic illustrations each showingthe structure of a common transfer sealing portion in a liquid crystaldisplay panel according to another embodiment of the present invention.FIGS. 19A, 19B, and 19C are plan views; and FIG. 19B is across-sectional view taken along line 19B-19B′ in FIG. 19A.

For example, a sufficient effect can be obtained even if the throughhole61 a in the resin layer 61 extends only part of the width of the sealingportion as shown in FIG. 19A. Such a structure will be particularlyeffective in the case where the final diameter of the common transfersection is smaller than the width of the sealing portion. The reason isthat, in such a case, it is possible to ignore any width increment dueto the sealant being pushed out by the common transfer section 60 towardthe side where the resin layer 61 lacks the throughhole (or dent) 61 a(i.e., toward the opposite side from the display region in FIG. 19A).

In the case where a resin layer that is formed for another purpose isconveniently utilized as the aforementioned resin layer, and must have alarge film thickness, the addition of the throughhole 61 a may result inthe width of the sealing portion being too thin. However, the structureas shown in FIG. 19A can counteract this problem and secure a sufficientseal width. Note that an excessively thin seal width may result inproblems associated with insufficient strength of the sealing portion.

FIG. 20 is a graph showing a relationship between the thickness of theresin layer 61 (depth of the throughhole 61 a) and the effect ofreducing the width of the sealing portion 32.

From FIG. 20, it can be seen that better effects are obtained as theresin film thickness is greater (i.e., the gap of the broad-gap regionis wider) and the main seal width is greater. In a simple simulation,the line width reduction effect can be expressed by the followingequation:{(main seal width×gap of main sealing portion)/(gap of main sealingportion+depth of dent in resin)}+common transfer diameter−(commontransfer diameter+main seal line width).

The “common transfer diameter” as used in the above equation is thefinal diameter of the common transfer substance in the case where thecommon transfer substance has no contact with the seal. Although theabove simulation equation does not take into account the shape of thecommon transfer substance and therefore would not accurately match theactual result, substantially similar effects will nonetheless beobtained.

In order to actually obtain the aforementioned effects, it is preferablethat the gap in the broad-gap region be at least about 10% greater thanthe gap of the sealing portion (i.e., the gap of any region of thesealing portion other than the broad-gap region) because the variationsin line width occurring during production must be absorbed to a certainextent. Although the above example illustrates an example where athroughhole 61 a is provided in the resin layer 61, a dent (hole) may beprovided instead of a throughhole. A dent may be formed by a halfexposure technique using a photosensitive resin (photoresist), forexample. When a dent is to be formed by a half exposure technique usinga positive type photosensitive resin, an exposure and development isperformed before reaching an irradiation time which would effectcomplete photolysis, so as to form a dent (hole). In the case of using anegative type, on the other hand, an exposure and development isperformed before reaching an irradiation time which would effectcomplete photocuring, so as to form a dent (hole). Forming a dent by ahalf exposure technique provides an advantage in that the dent depth iscontrollable. Note that a throughhole must not be formed in thephotosensitive resin layer in the case where leakage between conductivelayers which are provided above and below the photosensitive resin layercannot be tolerated; in such a case, it is suitable to form a hole(dent), as opposed to a complete throughhole.

The layer in which to form a throughhole or a dent (hole) is not limitedto an interlayer insulating film, but may also be a resin layer forforming a black matrix or an overcoating resin layer. If aphotosensitive resin layer is used, the throughhole or dent can beformed by a simple process. Alternatively an inorganic material layermay be used, although this would make it difficult to form a deepthroughhole or dent. It is usually preferable that the depth of any dentto be formed in the surface is in the range of about 1 μm to about 3 μm,when taking into account disadvantages such as the seal width becomingtoo thin.

It is preferable that the size of the throughhole or dent in the resinlayer (i.e., the size of the broad-gap region) be prescribed so as to besmaller than the maximum value of the final width of the common transfersection. In the embodiment shown in FIGS. 19A to 19D, thinning of thewidth of the sealing portion can be controlled based also on the patternand arrangement of the throughholes 61 a, so that an optimum structurecan be selected from a broader range. For example, similar effects wereconfirmed in the case where the edge of the throughhole 61 a was at aposition which was 300 μm outside of the center of the sealing portion32 along the width direction, under the same conditions as thosedescribed above. It would be preferable that the edge of the throughhole61 a be located at a position such that the outer edge of the sealingportion would not fall into the throughhole 61 a even in the case wherethe sealing portion has a minimum line width given the processvariations.

According to the present invention, there is provided a method which canefficiently produce a liquid crystal display panel having an undecreasedreliability even if a portion is formed within the liquid crystaldisplay panel which, under the conventional production method, wouldresult in a thick seal pattern width (e.g., a sealing junction or atransfer section). In particular, the present invention makes itpossible to efficiently produce a large-sized liquid crystal displaypanel by using a one drop filling technique.

While the present invention has been described with respect to preferredembodiments thereof, it will be apparent to those skilled in the artthat the disclosed invention may be modified in numerous ways and mayassume many embodiments other than those specifically described above.Accordingly, it is intended by the appended claims to cover allmodifications of the invention that fall within the true spirit andscope of the invention.

This non-provisional application claims priority under 35 USC §119(a) onPatent Applications No. 2004-208170 filed in Japan on Jul. 15, 2004 andNo. 2004-346915 filed in Japan on Nov. 30, 2004, the entire contents ofwhich are hereby incorporated by reference.

1. A liquid crystal display panel comprising: a first substrate; asecond substrate; a liquid crystal layer interposed between the firstsubstrate and the second substrate; a sealing portion surrounding theliquid crystal layer; a resin layer located on the sealing portion; anda transfer section arranged to establish an electrical connectionbetween the first substrate and the second substrate; the liquid crystaldisplay panel having a display region and a non-display regionsurrounding the display region; wherein the liquid crystal display panelincludes a broad-gap region within the non-display region, the broad-gapregion being a region in which a gap between the first substrate and thesecond substrate is partially increased, and the broad-gap regionincludes a dent in the resin layer; and at least a portion of thesealing portion and at least a portion of the transfer section arelocated within the dent.
 2. The liquid crystal display panel of claim 1,wherein the resin layer is located on the sealing portion.
 3. The liquidcrystal display panel according to claim 2, wherein the dent comprises athroughhole or hole formed in the resin layer.
 4. The liquid crystaldisplay panel according to claim 2, wherein the resin layer is aphotosensitive resin layer of a positive or negative type.
 5. The liquidcrystal display panel of claim 1, wherein the transfer section includesa photocurable material having conductive particles.
 6. The liquidcrystal display panel of claim 1, further comprising a light shieldinglayer located between the first and second substrates and spaced fromthe sealing portion by a gap.
 7. The liquid crystal display panel ofclaim 1, wherein a region on the first substrate corresponding to alocation of the transfer section is a light transmitting portion.
 8. Theliquid crystal display panel of claim 7, wherein the transfer section ismade of photocurable material.
 9. The liquid crystal display panel ofclaim 7, wherein the sealing portion is located within the lighttransmitting portion.
 10. The liquid crystal display panel of claim 9,wherein the transfer section and the sealing portion are made ofphotocurable material.
 11. The liquid crystal display panel of claim 1,wherein the dent has a width that is greater than that of the transfersection.
 12. The liquid crystal display panel of claim 1, wherein atleast a portion of the transfer section is located in the sealingportion and within the dent.
 13. A liquid crystal display panelcomprising: a first substrate; a second substrate; a liquid crystallayer interposed between the first substrate and the second substrate;and a sealing portion surrounding the liquid crystal layer; a transfersection arranged to establish an electrical connection between the firstsubstrate and the second substrate; the liquid crystal display panelhaving a display region and a non-display region surrounding the displayregion; wherein the liquid crystal display panel includes a broad-gapregion within the non-display region, the broad-gap region being aregion in which a gap between the first substrate and the secondsubstrate is partially increased; the broad-gap region includes a dentin a surface of the first substrate or the second substrate; the sealingportion is arranged on both sides of the transfer section; a portion ofthe sealing portion is provided in the dent such that one outer sidesurface of the sealing portion is located within the dent and anotherouter side surface of the sealing portion is located outside of thedent; and at least a portion of the transfer section is located withinthe dent.
 14. The liquid crystal display panel according to claim 13,further comprising a resin layer located on the sealing portion andarranged such that the dent is located in the resin layer.
 15. Theliquid crystal display panel according to claim 14, wherein the resinlayer is a photosensitive resin layer of a positive or negative type.16. The liquid crystal display panel of claim 14, wherein the dentcomprises a throughhole or hole formed in the resin layer.
 17. Theliquid crystal display panel of claim 13, wherein the transfer sectionincludes a photocurable material having conductive particles.
 18. Theliquid crystal display panel of claim 13, further comprising a lightshielding layer located between the first and second substrates andspaced from the sealing portion by a gap.
 19. The liquid crystal displaypanel of claim 13, wherein a region on the first substrate correspondingto a location of the transfer section is a light transmitting portion.20. The liquid crystal display panel of claim 19, wherein the transfersection is made of photocurable material.
 21. The liquid crystal displaypanel of claim 19, wherein the sealing portion is located within thelight transmitting portion.
 22. The liquid crystal display panel ofclaim 21, wherein the transfer section and the sealing portion are madeof photocurable material.
 23. The liquid crystal display panel of claim13, wherein the dent has a width that is greater than that of thetransfer section.
 24. A liquid crystal display panel comprising: a firstsubstrate; a second substrate; a liquid crystal layer interposed betweenthe first substrate and the second substrate; a sealing portionsurrounding the liquid crystal layer; a light shielding layer locatedbetween the first and second substrates and spaced in a horizontaldirection from the sealing portion such that no portion of the sealingportion is covered by the light shielding layer or any other lightshielding layer as viewed from above or below the first substrate or thesecond substrate; and a transfer section arranged to establish anelectrical connection between the first substrate and the secondsubstrate; the liquid crystal display panel having a display region anda non-display region surrounding the display region; wherein the liquidcrystal display panel includes a broad-gap region within the non-displayregion, the broad-gap region being a region in which a gap between thefirst substrate and the second substrate is partially increased, and thebroad-gap region includes a dent in a surface of the first substrate orthe second substrate; the transfer section or at least one portion ofthe sealing portion is located within the dent; each of the first andsecond substrates includes a light transmitting portion in a portionwhich at least partially corresponds to the transfer section or said atleast one portion of the sealing portion that is located within thedent; and each of the sealing portion and the transfer section are madeof photocurable material.
 25. The liquid crystal display panel accordingto claim 24, further comprising a resin layer located on the sealingportion and arranged such that the dent is located in the resin layer.26. The liquid crystal display panel according to claim 25, wherein theresin layer is a photosensitive resin layer of a positive or negativetype.
 27. The liquid crystal display panel of claim 25, wherein the dentcomprises a throughhole or hole formed in the resin layer.
 28. Theliquid crystal display panel of claim 27, wherein the photocurablematerial of the transfer section includes conductive particles.
 29. Theliquid crystal display panel of claim 24, further comprising a lightshielding layer located between the first and second substrates andspaced from the sealing portion by a gap.
 30. The liquid crystal displaypanel of claim 24, wherein a region on the first substrate correspondingto a location of the transfer section is a light transmitting portion.31. The liquid crystal display panel of claim 30, wherein the sealingportion is located within the light transmitting portion.
 32. The liquidcrystal display panel of claim 24, wherein the dent has a width that isgreater than that of the transfer section.
 33. A liquid crystal displaypanel comprising: a first substrate; a second substrate; a liquidcrystal layer interposed between the first substrate and the secondsubstrate; and a sealing portion surrounding the liquid crystal layer; atransfer section arranged to establish an electrical connection betweenthe first substrate and the second substrate; the liquid crystal displaypanel having a display region and a non-display region surrounding thedisplay region; wherein the liquid crystal display panel includes abroad-gap region within the non-display region, the broad-gap regionbeing a region in which a gap between the first substrate and the secondsubstrate is partially increased; the broad-gap region includes a dentin a surface of the first substrate or the second substrate; and atleast a portion of the sealing portion and a least a portion of thetransfer section are located within the dent; and the dent is located ata position that is spaced from a corner of the first substrate and acorner of the second substrate.
 34. The liquid crystal display panelaccording to claim 33, wherein the portion of the sealing portionlocated within the dent has a width that is greater than another portionof the sealing portion outside the dent and is a joint of the sealingportion.
 35. The liquid crystal display panel according to claim 33,further comprising a resin layer located on the sealing portion andarranged such that the dent is located in the resin layer.
 36. Theliquid crystal display panel according to claim 35, wherein the resinlayer is a photosensitive resin layer of a positive or negative type.37. The liquid crystal display panel according to claim 35, wherein thedent comprises a throughhole or hole formed in the resin layer.
 38. Theliquid crystal display panel of claim 33, further comprising a lightshielding layer located between the first and second substrates andspaced from the sealing portion by a gap.
 39. The liquid crystal displaypanel of claim 33, wherein a region on the first substrate correspondingto a location of the sealing portion is a light transmitting portion.40. The liquid crystal display panel of claim 39, wherein the sealingportion is made of photocurable material.
 41. The liquid crystal displaypanel of claim 33, wherein the dent has a width that is greater thanthat of the sealing portion.
 42. A liquid crystal display panelcomprising: a first substrate; a second substrate; a liquid crystallayer interposed between the first substrate and the second substrate;and a sealing portion completely surrounding the liquid crystal layerand including a junction where one end of the sealing portion meets withanother end of the sealing portion so as to completely surround theliquid crystal layer; a transfer section arranged to establish anelectrical connection between the first substrate and the secondsubstrate; the liquid crystal display panel having a display region anda non-display region surrounding the display region; wherein the liquidcrystal display panel includes a broad-gap region within the non-displayregion, the broad-gap region being a region in which a gap between thefirst substrate and the second substrate is partially increased; thebroad-gap region includes a dent in a surface of the first substrate orthe second substrate; the junction of the sealing portion is provided inthe dent; and at least a portion of the transfer section is located inthe sealing portion and within the dent.
 43. A liquid crystal displaypanel comprising: a first substrate; a second substrate; a liquidcrystal layer interposed between the first substrate and the secondsubstrate; a sealing portion surrounding the liquid crystal layer; alight shielding layer located between the first and second substratesand spaced in a horizontal direction from the sealing portion such thatthe sealing portion is not covered by the light shielding layer or anyother light shielding layer; and a transfer section arranged toestablish an electrical connection between the first substrate and thesecond substrate; the liquid crystal display panel having a displayregion and a non-display region surrounding the display region; whereinthe liquid crystal display panel includes a broad-gap region within thenon-display region, the broad-gap region being a region in which a gapbetween the first substrate and the second substrate is partiallyincreased, and the broad-gap region includes a dent in a surface of thefirst substrate or the second substrate; the transfer section or atleast one portion of the sealing portion is located within the dent;each of the first and second substrates includes a light transmittingportion in a portion which at least partially corresponds to thetransfer section or said at least one portion of the sealing portionthat is located within the dent; each of the sealing portion and thetransfer section are made of photocurable material; and the lightshielding layer has a recess formed therein that is arranged tocompletely expose all of the dent as viewed from above or below thedent.